An Insight into the Diffusion of Unsaturated Polyester (UP) Resin into Expanded Graphite (EG) to Improve the Mechanical Properties of the UP/EG Composites

Abstract

Polymer/expanded graphite (EG) nanocomposites have great importance in many industrial applications mainly due to their high electrical/thermal conductivity or flame retardancy. However, to fully employ the benefits of polymer/EG nanocomposites one must consider the high degree of porosity of EG. The high degree of porosity of EG can deteriorate the composites’ mechanical properties if the polymer chains cannot diffuse completely into the EG pores. In this article, an insight is given into the diffusion of unsaturated isophthalic polyester (UP) resin, consisting of a combination of maleic anhydride and isophthalic anhydride in the resin backbone, with two viscosities, into the pores of the EG particles of various degrees of porosity. The diffusion experiments were carried out on compressed EG tablets with the same density but different porosity due to the different porosity of the EG particles. The results showed that the diffusion rate of the UP resin with higher viscosity slightly decreased when the EG porosity decreased but, in the opposite way, it strongly increased for the low viscosity UP resin. The EG nanocomposites samples were molded at varying pressures. The micrographs of the fractured surfaces of the EG nanocomposites showed that the EG pores were not filled with resin, thus the EG nanocomposites had residual pores. It was found that composites containing EGs with higher expansion ratio and larger particles and pores showed larger residual pores. Furthermore, the composites prepared with the more viscous UP resin showed more residual pores. By applying a pressure of 10?bar instead of 1?bar, a reduction of 7–20% in the residual pores of the nanocomposites was observed which led to improved mechanical properties by up to 20% in flexural strength for the EG with the highest expansion ratio.